Method for forming outerlayer on a curved surface

ABSTRACT

A method for forming an outside layer on a curved surface and a kit for the same purpose is disclosed. The method here is achieved by the following steps: (a) providing an assembling kit containing a first set and a second set; (b) assembling the first set and a second set together to form an outside layer on the curved surface. The first set of the assembling kit consists of a central hexagon and three pentagons. The second set consists of one binding hexagon and two peripheral hexagons. As the first set and the second set is combined together, only one respective edge of the central hexagon abuts one corresponding edge of each binding hexagon.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention is related to a method for forming an outside layer on acurved surface, and especially, relates to a method for forming anoutside layer on ball-shaped surface.

2. Description of Related Art

So far, the most popular methods for forming a pattern on a curvedsurface such as a ball-surface can be the piece-up method or integralmolding method. The direct-fixing method is achieved by preparing awell-printed outside layer which is big enough to cover the curvedsurface. Then the outside layer is fixed to cover the target curvedsurface. However, the method illustrated above easily generates wrinkleson the surface of the fixed outside layer or the edges thereof.Therefore, the appearance of the achieved outside layer on the curvedsurface is unattractive. Most important of all, the outside layer on thecurved surface causes an unrealistic appearance, especially for somepatterns, pictures, or photos. On the other hand, the conventionalpiece-up method of assembling small pieces of pads together is costlysince it is labor intensive and slow. Moreover, as the curved surface issmall, the method is not practical. In addition, gaps inevitably occurbetween the pieces used in the traditional piece-up method and theycause further difficulties during the assembling.

Taking assembly of a soccer ball pattern on a ball surface for example,a pad made of ten hexagons and six pentagons (see FIG. 1) are commonlyprepared in the traditional piece-up method. The pad shown FIG. 1 isused for covering a hemi-spherical surface and is cut into severalsingle pentagons and hexagons before assembling. Then all the pentagonsand hexagons are adhered or stitched to the hemi-spherical surfaceindividually by labor. Therefore, the traditional piece-up method needsconsiderable skilled labors, which furthermore is time-consuming. In thetraditional piece-up method, the gaps between the pentagons and thehexagon cannot be well controlled since too many single pads need to beadhered or stitched. Additionally, the assembly is difficult as the sizeof the curved surface is small since the angle or the side length of thepentagons or the hexagons cannot be well cut. In most cases, somedifferences between pentagons (or hexagons) are generated naturally whenparticularly small curved surfaces are involved.

Imperfect pictures or the patterns formed through the direct-fixingmethod are particularly hard to be improved after the big sheet of coverof pictures or patterns is adhered to the curved surface. In otherwords, it is very difficult to prevent or remove the wrinkles occurringon the cover sheet, especially for the adhesion or stitching of thesheet on a surface with high degree of curvature (for example, the ballsurface).

Therefore, it is desirable to provide an improved method to mitigate theaforementioned problems.

SUMMARY OF THE INVENTION

The method of the present invention relates to a method for forming anouter layer on curved surface, and which can facilitate the assembly,reduce wrinkling, reduce variations between gaps, save the time inassembly of appropriate products, and reduce the cost of products.

The present invention further relates to a kit for forming an outsidelayer on a curved surface. This kit will facilitate the assembling,reduce the quantity of wrinkles, reduce the variations between gaps,save time in assembly of products made using this method, and reduce thecost for assembly of such products.

To achieve the purpose above, the method for forming an outside layer ona curved surface of the present invention comprises the following steps:(A) providing a substrate having a curved surface, a first combiningmember consisting of a central hexagon and three pentagons, and threesecond combining members consisting of a binding hexagon and twoperipheral hexagons; and (B) combining and fixing the first combiningmember, and the second combining members on the curved surface of thesubstrate. Among the first combining member and the second combiningmember, any two sides of two different pentagons of the same firstcombining member are not next to each other. In addition, one side ofeach pentagon is next to a respective side of the central hexagon of thefirst combining member or the central hexagon of the first combiningmember is next to one side of the pentagon. Moreover, each bindinghexagon is next to a respective side of the peripheral hexagon of thesecond combining member, and any two sides of the two differentperipheral hexagons of the same second combining member are not next toeach other. Furthermore, when the first combining member, and the secondcombining member are combined together on the curved surface, at leastone side of the central hexagon of the first combining member is next toone side of the binding hexagon of the second combining member.

In general, after the first combining member and the second combingmember is assembled together, protrusions, or kinks happen on the edgeof the first combining member and the second combing member. Hence, themethod of the present invention can optionally further comprise a stepof (C) making the first edge of the first combining member and thesecond edge of the second combining member comply with the third edge ofthe curved surface after the first combining member and the secondcombining member are fixed on the curved surface. Step (C) is carriedout after step (B) is performed in the method of the present invention.The first edge of the first combining member and the second edge of thesecond combining member can be made to comply with the third edge of thecurved surface through any conventional process in step (C). Preferably,the first edge of the first combining member and the second edge of thesecond combining member are cut or folded along the third edge of thecurved surface.

The kit of the present invention includes: a first combining memberhaving a central hexagon and three pentagons; three second combiningmembers. Each second combining member has a binding hexagon and twoperipheral hexagons. Among them, any two sides of two differentpentagons of the same first combining member are not next to each other.Furthermore, one side of each pentagon is next to one side of thecentral hexagon of the first combining member or the central hexagon ofthe first combining member is next to one side of the pentagon.Moreover, each binding hexagon is next to one side of the peripheralhexagon of the second combining member. Any two sides of the twodifferent peripheral hexagons of the same second combining member arenot next to each other.

The hexagons (for example, the central hexagons, the binding hexagon,and the peripheral hexagons) of the kit of the present invention orthose of the method of the present invention can be any conventionalhexagons. Preferably, each angle between any two neighboring sides ofthe same hexagon in the first combining member or in the secondcombining member has the same angle. In other words, the shape of thehexagons of the present invention is preferred to be the same. Morepreferably, each side of each hexagon in the first combining member orin the second combining member has the same length. In other words, thesizes of the hexagon in the first combining member or in the secondcombining member are more preferable to be the same. Likewise, thepentagons of the kit of the present invention or those of the method ofthe present invention can be any conventional pentagons. Preferably,each side of the same pentagon in the first combining member has thesame length. In other words, the pentagons of the present invention arepreferred to be in the same shape. More preferably, each side of allpentagons in the first combining member has the same length. In otherwords, the pentagons of the present invention are more preferred to beof the same size. The patterns or the colors on the surface of thepentagons, the patterns or the colors on the surface of the centralhexagons of the first combining member, the patterns or the colors onthe surface of the binding hexagon, and the patterns or the colors onthe surface of the peripheral hexagons can be the same or different.Preferably, the patterns or the colors on the surface of the pentagons,the patterns or the colors on the surface of the central hexagons of thefirst combining member, the patterns or the colors on the surface of thebinding hexagon, and the patterns or the colors on the surface of theperipheral hexagons are different.

The curved surface suitable for the kit of the present invention or themethod of the present invention can be any conventional curved surface.Preferably, the curved surface is an irregular curved surface, or thesurface of a sphere or a hemi-sphere.

Other objects, advantages, and novel features of the invention willbecome more apparent from the following detailed description when takenin conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view of a pad for constructing asoccer ball in the prior art.

FIG. 2A is a view of the first combining member of the kit of thepresent invention.

FIG. 2B is a view of the second combining member of the kit of thepresent invention.

FIG. 2C is a view of the assembling of the first combining member andthree second combining members of the kit of the first embodiment of thepresent invention.

FIG. 3 is a side view of an assembled sphere produced from the kit ofthe second embodiment of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

With reference to FIG. 2A, a first combining member 10 of the presentinvention is shown. The first combining member 10 of the presentinvention comprises a central hexagon 1 1 and three pentagons 12, 13,14. As shown in FIG. 2A, one side of each pentagon 12, 13, 14 connectsto a respective side of the central hexagon 11 in an alternating manner.That is, the central hexagon 11 is among the three pentagons 12, 13, 14,which are regularly separate from each other. With reference to FIG. 2B,a second combining member 20 of the present invention is shown. Thesecond combining member 20 of the present invention comprises a bindinghexagon 21 connectedly fitted between two peripheral hexagons 22, 23.The binding hexagon may be described as having an upper half and a lowerhalf, each half having three faces, sequentially A, B and C. As shown inFIG. 2B, one side of each of the peripheral hexagons 22, 23 respectivelycontacts faces A and C, such that the peripheral hexagons are separatefrom each other. Referring to FIG. 2C, an assembly of the firstcombining member and three second combining members of the kit of thefirst embodiment of the present invention is shown. As the elements ofthe kit of the present invention are assembled, one of first combiningmembers 10 and three of the second combining members 20, 30,40 arearranged on a curved surface (not shown in FIG. 2C) through adhesion orstitching. One side of the binding hexagon 21 which is not next to theperipheral hexagon 22 of the second combining member 20 is arranged tobe next to the available side of the central hexagon 11 of the firstcombining member 11. Moreover, one available side of the peripheralhexagon 22 of the second combining member 20 is next to a correspondingavailable side of the pentagon 12 of the first combining member 10.Likewise, one available side of the peripheral hexagon 23 of the secondcombining member 20 is next to a corresponding available side of thepentagon 13 of the first combining member 10. One available side of thebinding hexagon 31 of the second combining member 20 is next to acorresponding available side of the central hexagon 11 of the firstcombining member 10. One available side of the binding hexagon 41 of thesecond combining member 20 is next to a corresponding available side ofthe central hexagon 11 of the first combining member 10. Furthermore,one of the available sides of the peripheral hexagon 32 of the secondcombining member 20 is next to a corresponding available side of thepentagon 13 of the second combining member 10. Similarly, one of theavailable sides of the peripheral hexagon 33 of the second combiningmember 20 is next to a corresponding available side of the pentagon 14of the second combining member 10. One of the available sides of theperipheral hexagon 42 of the second combining member 20 is next to acorresponding available side of the pentagon 12 of the second combiningmember 10. One of the available sides of the peripheral hexagon 43 ofthe second combining member 20 is next to a corresponding available sideof the pentagon 14 of the second combining member 10.

As the assembly progresses, the binding hexagon 21 of the secondcombining member 20 will be located between the pentagons 12, 13 of thefirst combining member 10. The binding hexagon 31 of the secondcombining member 30 will be located between the pentagons 13, 14 of thefirst combining member 10. The binding hexagon 41 of the secondcombining member 20 will be located between the pentagons 12, 14 of thefirst combining member 10.

FIG. 3 shows a complete assembly of the kit of the second embodiment ofthe present invention on a ball surface. The Y-shaped line 100 in FIG. 3shows the location of the first combining member of the presentinvention after the kit is assembled. The central hexagon 11, thepentagons 12, 13, 14 of the first combining member can be found on thesurface of the ball in FIG. 3 easily. The other three bent lines 200,300, 400 show the location of the second combining member of the presentinvention after the kit is assembled. As shown in FIG. 3, the bindinghexagon 21 of the second combining member is located between thepentagons 12, 13 of the first combining member. The binding hexagon 31of the second combining member is located between the pentagons 13, 14of the first combining member. The binding hexagon 41 of the secondcombining member is located between the pentagons 12, 14 of the firstcombining member.

Since an integrated set of pads such as the first combining member andthe second combining member is used, the labor and the time required forassembling can be obviously reduced relative to the prior art. Moreover,the differences of the gaps between the sides of the pentagons or thehexagons can be reduced since fewer gaps exist.

Although the present invention has been explained in relation to itspreferred embodiment, it is to be understood that many other possiblemodifications and variations can be made without departing from thespirit and scope of the invention as hereinafter claimed.

1-9. (canceled)
 10. A kit for forming an outside layer on a curvedsurface, comprising: a first combining member having a central hexagonand three pentagons; three second combining members having a bindinghexagon and two peripheral hexagons; wherein any two sides of twodifferent pentagons of the same first combining member are not next toeach other, one side of each pentagon is next to a respective side ofthe central hexagon of the first combining member or the central hexagonof the first combining member is next to a respective of the pentagon,each binding hexagon is next to one side of the peripheral hexagon ofthe second combining member, and any two sides of the two differentperipheral hexagons of the same second combining member are not next toeach other.
 11. The kit as claimed in claim 10, further comprising asubstrate having a curved surface with at least one edge.
 12. The kit asclaimed in claim 11, wherein the first combining member and the secondcombining member is fixed on the substrate, and at least one side of thecentral hexagon of the first combining member is next to one side of thebinding hexagon of the second combining member.
 13. The kit as claimedin claim 10, wherein each angle between any two neighboring sides of thesame hexagon in the first combining member or in the second combiningmember has the same angle.
 14. The kit as claimed in claim 10, whereineach side of each hexagon in the first combining member or in the secondcombining member has the same length.
 15. The kit as claimed in claim10, wherein each side of the same pentagon in the first combining memberhas the same length.
 16. The kit as claimed in claim 10, wherein eachside of all pentagons in the first combining member has the same length.17. The kit as claimed in claim 10, wherein patterns on surfaces of thepentagons, patterns on surfaces of the central hexagons of the firstcombining member, patterns on surfaces of the binding hexagon, and thepatterns on the surfaces of the peripheral hexagons are different fromeach other in wherein patterns on surfaces of the pentagons, patterns onsurfaces of the central hexagons of the first combining member, patternson surfaces of the binding hexagon, and the patterns on the surfaces ofthe peripheral hexagons are different from each other in appearance.